Methods and devices for heating liquid for injection into a wellbore or pipeline system

ABSTRACT

Super heater systems include self-contained units which are easily transported to remote locations. Such super heater systems include heat exchanger assemblies adapted to heat liquid on-the-fly (i.e., directly from the supply source to a wellbore or pipeline system. A heat exchange assembly may include a first header with a plurality of first header layers in alternating fluid communication, and a second header with a plurality of second header layers in alternating fluid communication. A plurality of heat exchange coils can be coupled between the first header and the second header such that the heat exchange coils are exposed to heat generated by a burner manifold. Other aspects, embodiments, and features are also claimed and described.

TECHNICAL FIELD

The following relates generally to oil and gas production, and morespecifically to methods and devices for heating a liquid for injectioninto a wellbore or into a pipeline system.

BACKGROUND

In connection with production of oil or gas from a geological formation,a wellbore is typically drilled using subterranean drill bits, and thewellbore is typically lined with a casing that is cemented into thewellbore. After the wellbore is completed, hydraulic fracturing, alsoknown as “fracing” may be employed to create and/or restore smallfractures in the formation to stimulate production from new and existingoil and gas wells. The fractures can form conduits that enable the oilor gas to flow more easily from the tight sands or shales to thewellbore.

A common method to create fractures in the formation is to pump afracturing fluid into the wellbore at a sufficient rate and pressure toovercome the tensile strength of the formation, creating cracks orfractures extending from the wellbore. With each crack or fracture, thefracturing fluid can continue further into the formation, extending thecrack further and further into the formation. The extended fracturescreate sufficient permeability to facilitate the flow of formationfluids to the well.

The fracturing fluid typically includes a slurry of proppants, water andoptional chemical additives. The proppants, such as grains of sand,ceramic, and/or other particulates, are adapted to maintain fracturewidth, or at least slow its decline, and provide porosity to allow theformation fluids to flow out of the formation. The water is often heatedto a target temperature (e.g., 40° F. to 120° F. (4.4° C. to 48.9° C.))before the fracturing fluid is injected into the wellbore. The targettemperature may depend on the geologic formation and chemicals used. Afurther result of heating the water prior to mixing with chemicals isthe reduction of amount of chemicals that may be required for thehydraulic fracturing operation. In addition, a lower density of theheated water reduces the pressure on the pipes and connections andthereby reduces the risk for mechanical failure. In colder months and incolder environments, the available water sources are typically atunsuitably code temperatures for the fracturing process. It is thereforedesirable to heat the available water to a temperature suitable for thefracturing process prior to the water and fracturing fluids being pumpeddown the borehole.

BRIEF SUMMARY OF SOME EXAMPLES

Various aspects of the present disclosure include super heater systemsadapted to efficiently heat large quantities of liquid for use infracturing fluids. According to at least some embodiments, such superheater systems can include a fuel storage and supply system in fluidcommunication with a burner manifold. The burner manifold can be adaptedto generate heat by combusting fuel received from the fuel storage andsupply system. At least one pump may be in fluid communication with aheat exchanger assembly. The heat exchanger assembly may include a firstheader at a first longitudinal end. The first header can include aplurality of first header layers in alternating fluid communication. Asecond header at a second longitudinal end can include a plurality ofsecond header layers in alternating fluid communication. A plurality ofheat exchange coils may extend between and may be coupled to the firstheader and the second header. The plurality of heat exchange coils maybe exposed to the heat generated by the burner manifold.

Additional aspects of the present disclosure include a burner boxesemployable in a super heater system. In one or more embodiments, aburner box may include a plurality of heat exchange coils, with a firstheader coupled to a first longitudinal end of the heat exchange coils,and a second header coupled to an opposing longitudinal end of the heatexchange coils. The first header and the second header can each includea plurality of header layers in alternating fluid communication.

Further aspects of the present disclosure include heat exchangerassemblies adapted for use with a super heater system. In at least someembodiments, a heat exchanger assembly can include a plurality of heatexchange coils, with a first header coupled to a first longitudinal endof the heat exchange coils, and a second header coupled to an opposingsecond longitudinal end of the heat exchange coils. The first header caninclude a plurality of header layers, where at least some of the headerlayers of the first header are in fluid communications with at least oneother header layer of the first header. The second header can alsoinclude a plurality of header layers, where at least some of the headerlayers of the second header are in fluid communication with at least oneother header layer of the second header.

Other aspects of the present disclosure include methods of making asuper heater system. One or more implementations of such methods mayinclude forming a first header to include a plurality of header layersdisposed in alternating fluid communication. A second header can also beformed to include a plurality of header layers disposed in alternatingfluid communication. A longitudinal end of a plurality of heat exchangecoils can be coupled to the first header and an opposing longitudinalend of the plurality of heat exchange coils to the second header.

Still additional aspects of the present disclosure include operationalmethods of a heat exchanger assembly. At least one implementation ofsuch methods may include introducing a liquid into a header layer of afirst header. The liquid can be caused to flow from the header layers ofthe first header, through a plurality of heat exchange coils into aheader layer of a second header. The liquid can further be caused toflow from the header layer of the second header to another header layerof the second header. From the other header layer of the second header,the liquid can be caused to flow through another plurality of heatexchange coils to another header layer of the first header.

Other aspects, embodiments, and features within the scope of the presentdisclosure will become apparent to those of ordinary skill in the artupon reviewing the following detailed description.

DRAWINGS

FIG. 1 illustrates a front elevation view of a super heater according toat least one example.

FIG. 2 is an isometric view of select components of a heat exchangerassembly according to at least one example.

FIG. 3 is schematic diagram illustrating at least one example ofalternating fluid communication between header layers and betweenheaders.

FIG. 4 is a diagram illustrating flow of a liquid through the heatexchanger assembly depicted in FIGS. 2 and 3.

FIG. 5 is an isometric view illustrating select features of a housingaccording to at least some examples.

FIG. 6 is an isometric view illustrating select components of an outletinterface assembly according to at least one example.

FIG. 7 is a flow diagram depicting various steps for at least oneimplementation of a method for making a super heater system.

DETAILED DESCRIPTION

The illustrations presented herein are, in some instances, not actualviews of any particular heat exchanger assembly, heat exchange coils,headers, housing, outlet interface assembly, or super heater system, butare merely idealized representations which are employed to describe thepresent disclosure. Additionally, elements common between figures mayretain the same numerical designation.

Various embodiments of the present disclosure comprise super heatersystems with heat exchanger assemblies adapted to facilitate fluidheating at relatively high flow rates. Referring to FIG. 1, an exampleof a super heater system 100 is shown. The super heater system 100includes a trailer 102 suitable for transport to remote oil field sites.The trailer 102 is adapted to be coupled to a vehicle 104, such as atractor unit. A fuel storage and supply system 106 is positioned on thetrailer 102 and is positioned in fluid communication with one or morecomponents of a burner box 108. In some embodiments, the fuel storageand supply system 106 may contain a combustible fuel such as propane ora diesel engine fuel. This fuel can be provided by the fuel storage andsupply system 106 to one or more components of the burner box 108.

A pump 110 can be placed in fluid communication with the burner box 108for providing unheated fluid to the burner box 108. In some embodiments,the super heater system 100 further includes a boost pump 112 adapted toprovide additional pumping capabilities to the system. The pump 110, andoptionally the boost pump 112, is/are used to draw a fluid (e.g., water)from a fluid source (e.g., a frac tank, an open reservoir often referredto as a pit by those of skill in the art) and supply the fluid to one ormore components of the burner box 108. In at least some embodiments, thepump 110, in combination with or independent from the boost pump 112,can be adapted to pump the fluid into the burner box 108 at a rategreater than about 25 barrels (e.g., about 1,050 gallons, 3,974 liters)per minute. In some embodiments, the fluid can be pumped into the burnerbox 108 at a rate of about 30 barrels (e.g., about 1,260 gallons, 4,770liters) or more per minute.

In some instances, a hydraulic fracturing crew (frac crew) will usebetween about 30 barrels (e.g., about 1,260 gallons, 4,770 liters) and50 barrels (e.g., about 2,100 gallons, 7,949 liters) of heated liquidper minute in the fracturing process. According to an aspect of thepresent disclosure, the super heater system 100 is capable of heatingfluid to a target temperature (e.g., between about 40° F. and 120° F.(4.4° C. to 48.9° C.)) at a rate of about 30 barrels (e.g., about 1,260gallons, 4,770 liters) or more per minute. In some embodiments, thesuper heater system 100 is capable of heating the fluid to the desiredtemperature at a rate between 30 barrels (e.g., about 1,260 gallons,4,770 liters) and 58 barrels (e.g., about 2,436 gallons, 9,221 liters)per minute.

In order to facilitate heating such relatively high rates of liquid to atarget temperature, the burner box 108 includes a housing 114 sized andconfigured to accommodate a heat exchanger assembly adapted to receiveand heat such sufficiently high liquid flows. FIG. 2 is an isometricview illustrating select components of a heat exchanger assembly 202according to at least one example. The heat exchanger assembly 202includes a plurality of heat exchange coils 204 extending between afirst header 206 at a first longitudinal end and a second header 208 atan opposing longitudinal end of the heat exchanger assembly 202.

The heat exchange coils 204 can extend over a burner manifold 210 thatis in fluid communication with the fuel storage and supply system 106(see FIG. 1), and adapted to supply heat to the heat exchange coils 204by burning the fuel. The burner manifold 210 can include one or morearrays of combustion cups coupled with the fuel storage and supplysystem 106 to receive a supply of fuel therefrom. When the burnermanifold 210 is ignited, each combustion cup may generate heat in theform of a flame.

The heat exchange coils 204 may each be formed of a material adapted tosuitably facilitate conductive heat transfer (e.g., a non-insulativematerial), such as a metal, metal alloy, etc. In one or moreembodiments, the heat exchange coils 204 are each formed of a pipe, suchas a schedule 80, 2-inch (5.08 centimeters) pipe, in at leastsubstantially equal lengths between about 15 feet (4.572 meters) andabout 30 feet (9.144 meters). In at least one embodiment, the heatexchange coils 204 are each formed from a pipe of about 21.25 feet(6.477 meters) in length.

The first and second headers 206, 208 can include a plurality of headerlevels or layers 212. For instance, the first header 206 in theillustrated embodiment includes six (6) header layers (or first headerlayers) 212A through 212F, and the second header 208 also includessimilar header layers (or second header layers) 212. Although six headerlayers 212 are illustrated, other embodiments may include differentnumbers of header layers. In at least some embodiments, each headerlayer 212 is generally shaped as a hollow cuboid in which six facesenclose, or at least substantially enclose, a hollow volume throughwhich liquid can flow. However, other embodiments may employ differentshapes for the header layers 212. The header layers 212 may be formed ofa material similar to the heat exchange coils 204. For example, theheader layers 212 may be formed from a metal, metal alloy, etc. Eachheader layer 212 of a respective header 206 or 208 is positioned oneabove another as illustrated.

Each of the heat exchange coils 204 is coupled to a header layer 212 ofthe first header 206 and the second header 208. By way of example andnot limitation, the heat exchange coils 204 can be coupled to a layer ofthe first header 206 and the second header 208 by various means, such asa threaded connection, a weld, an adhesive, etc., as well as one or morecombinations. With a generally cuboid shape (or other shape withsufficient surface area) each header layer 212 can include multiplesublayers of heat exchange coils 204 coupled thereto in someembodiments. For example, the header layer 212A of the first header 206includes two sublayers of heat exchange coils 204, a lower layer 204Aand an upper layer 204B. These sublayers are more clearly shown in FIG.3, where the heat exchange coils 204 are illustrated in broken linesassociated with each header layer 212. Such sublayers can increase thenumber of heat exchange coils 204 employed in the heat exchangerassembly 202, facilitating the relatively high flow rates through theheat exchanger assembly 202 without substantially increasing thevelocity of the liquid. A slower flowing liquid will be able to spendmore time exposed to the heat from the burner manifold 210, enabling theliquid adequate time to heat to a target temperature. Additionally, anincrease in the number of heat exchange coils 204 facilitates anincrease in the total surface area of the heat exchange coils 204, whichmay facilitate more efficient heat transfer.

According to an aspect of the present disclosure, some of the headerlayers 212 are positioned in fluid communication with another headerlayer 212 of the same header 206 or 208 so that the liquid to be heatedcan flow from one header layer 212 to another. Furthermore, some of theheader layers 212 are positioned without direct fluid communication witha header layer 212 directly above and/or below. FIG. 3 is a schematicdiagram illustrating at least one example of such fluid communicationbetween header layers 212 of the first header 206 and the second header208. Each of the headers 206, 208 includes six header layers 212, withheader layers 212A through 212F shown as part of the first header 206,and header layers 212G through 212L shown as part of the second header208.

At least one of the headers 206, 208 includes an inlet for receivingliquid from the pump 110 (see FIG. 1), and at least one of the headers206, 208 includes an outlet from which heated liquid is output. In thedepicted embodiment, the first (or lowest) header layer 212A of thefirst header 206 includes an inlet 302 and the sixth (or highest) headerlayer 212F of the first header 206 includes an outlet 304. In thedepicted embodiment, the header layers 212 of the first header 206 arein a fluid communication configuration referred to herein as alternatingfluid communication. For example, the lowest header layer 212A is not influid communication with any other header layers 212 of the first header206. Moving upward, the next header layer 212B is shown in fluidcommunication with the header layer 212C disposed directly above. Thatis, fluid can flow between the header layer 212B and the header layer212C through the conduit 306. The header layer 212C is not in fluidcommunication with the header layer 212D directly above, but the headerlayer 212D is in fluid communication with the header layer 212E directlyabove it by means of the conduit 308. Finally, the highest header layer212F is not in fluid communication with any of the other header layers212 of the first header 206.

The header layers 212 of the second header 208 are also configured inalternating fluid communication. As shown, the first (or lowest) headerlayer 212G is in fluid communication with the header layer 212Hpositioned directly above by means of the conduit 310, but the headerlayer 212H is not in fluid communication with the above header layer212I. The header layer 212I is in fluid communication with the headerlayer 212J directly above by means of the conduit 312, and the headerlayer 212J is not in fluid communication with the next upward headerlayer 212K. Finally, the header layer 212K is in fluid communicationwith sixth (or highest) header layer 212L via the conduit 314.

The alternating fluid communication for the header layers 212 of thefirst header 206 can be configured to alternate with the alternatingfluid communication of the header layers 212 of the second header 208.For instance, as can be seen in FIG. 3, the header layers 212 of thefirst header 206 which are in fluid communication correspond to headerlayers 212 of the second header 208 which are not in fluidcommunication. Similarly, the header layers 212 of the second header 208which are in fluid communication correspond to header layers 212 of thefirst header 206 which are not in fluid communication. For example,where the first header 206 includes header layer 212B and header layer212C in fluid communication, the corresponding header layers 212H and212I of the second header 208 are not in fluid communication. Similarly,where the lowest header layer 212G of the second header 208 is in fluidcommunication with the header layer 212H, the lowest header layer 212Aof the first header 206 is not in fluid communication with the nexthigher header layer 212B.

The alternating fluid communication configuration facilitates the flowof liquid through the heat exchanger assembly 202. FIG. 4 is a diagramillustrating flow of a liquid through the heat exchanger assembly 202according to at least one example. Both the first header 206 and thesecond header 208 are shown, as well as some of the heat exchange coils204 extending between the two headers 206, 208. Initially, a liquid isintroduced into the first header 206 by means of the inlet 302. Theinlet 302 is in fluid communication with the lowest header layer 212A ofthe first header 206. As the liquid fills the lowest header layer 212Aof the first header 206, the liquid flows into and through the heatexchange coils 402 in the direction of the arrows toward the secondheader 208 and begins to fill the lowest header layer 212G of the secondheader 208.

When the lowest header layer 212G of the second header 208 is filled,the liquid can flow into the next upward header layer 212H of the secondheader 208 through the conduit 310 (see FIG. 3) as indicated by thearrow extending between the two header layers in FIG. 4. As the headerlayer 212H of the second header 208 fills, the liquid flows into theheat exchange coils 404 in the direction of the arrows toward the firstheader 206 and begins to fill the header layer 212B of the first header206.

When the header layer 212B of the first header 206 is filled, the liquidcan flow into the next upward header layer 212C of the first header 206through the conduit 306 (see FIG. 3) as indicated by the arrow extendingbetween the two header layers in FIG. 4. As the header layer 212C of thefirst header 206 fills, the liquid flows into the heat exchange coils406 in the direction of the arrows toward the second header 208 andbegins to fill the header layer 212I of the second header 208.

When the header layer 212I of the second header 208 is filled, theliquid can flow into the next upward header layer 212J of the secondheader 208 through the conduit 312 (see FIG. 3) as indicated by thearrow extending between the two header layers in FIG. 4. As the headerlayer 212J of the second header 208 fills, the liquid flows into theheat exchange coils 408 in the direction of the arrows toward the firstheader 206 and begins to fill the header layer 212D of the first header206.

When the header layer 212D of the first header 206 is filled, the liquidcan flow into the next upward header layer 212E of the first header 206through the conduit 308 (see FIG. 3) as indicated by the arrow extendingbetween the two header layers in FIG. 4. As the header layer 212E of thefirst header 206 fills, the liquid flows into the heat exchange coils410 in the direction of the arrows toward the second header 208 andbegins to fill the header layer 212K of the second header 208.

When the header layer 212K of the second header 208 is filled, theliquid can flow into the highest header layer 212L of the second header208 through the conduit 314 (see FIG. 3) as indicated by the arrowextending between the two header layers in FIG. 4. As the header layer212L of the second header 208 fills, the liquid flows into the heatexchange coils 412 in the direction of the arrows toward the firstheader 206 and begins to fill the highest header layer 212F of the firstheader 206. The liquid in the highest header layer 212F of the firstheader 206 can exit from the heat exchanger assembly 202 through theoutlet 304.

In the depicted example, the liquid can flow through each of the heatexchange coils 402, 404, 406, 408, 410, 412 in parallel. Flowing inparallel refers to the concept that different volumes of liquid flowthrough each heat exchange coil of a given header layer 212 withoutflowing through any of the other heat exchange coils for that layer. Forinstance, a volume of liquid that flows through one of the heat exchangecoils 402 will generally not flow through any of the other heat exchangecoils 402. At the same time that the volume of liquid is flowing throughthe particular one of the heat exchange coils 402, different volumes ofliquid will flow through each of the other heat exchange coils 402.

Each time the liquid passes through the heat exchange coils 402, 404,406, 408, 410, 412, the liquid passes over the burner manifold 210. Whenthe burner manifold 210 is lit, the liquid flowing through the heatexchange coils is exposed to heat from flames of the burner manifold210, increasing the temperature of the liquid. In one or moreembodiments, the temperature of the liquid can be increased byapproximately 30°-85° F. at a rate between about 30 barrels (1,260gallons, 4,770 liters) per minute to 58 barrels (2,436 gallons, 9,221liters) per minute of continuous pumping flow. The change in temperatureat least partially dependent on the flow rate. For example, at a lowflow rate of about 10 barrels (420 gallons, 1,589 liters) per minute,the temperature of the liquid may be increased by as much as about 175°F. In another example, a flow rate of about 30 barrels (1,260 gallons,4,770 liters) per minute may result in an increase in the temperature ofthe liquid by as much as approximately 85° F. In yet another example, aflow rate of about 50 barrels (2,100 gallons, 7,949 liters) may resultin an increase in the temperature of the liquid by as much as about 30°F.

The heat exchanger assembly 202 can be enclosed within the housing 114(see FIG. 1). The housing 114 can retain the heat generated by theburner manifold to inhibit heat loss, and to protect users from dangersassociated with the heat. FIG. 5 is an isometric view of a housing 114according to at least one example. The housing 114 includes an opening502 adapted to enable exhaust gases from the burner manifold 210 (seeFIG. 2) to exit from the housing 114. The housing may be formed from ametal or metal alloy material, and can be sized and shaped to at leastsubstantially enclose the heat exchanger assembly 202 (see FIG. 2) andthe burner manifold 210 (see FIG. 2). The housing 114 may include aninsulation material (not shown) disposed thereon for inhibiting theconductive flow of heat from inside the housing 114 outward.

The housing 114 includes at least one rib 504 coupled to a sidewall 506of the housing 114. The at least one rib 504 is adapted to stiffen thesidewall 506 to which it is coupled. One or more ribs 504 can be coupledto an outside surface (as illustrated) and/or an inside surface of thesidewall 506. The one or more ribs 504 are disposed on the sidewall torun generally in a direction of the grain of the sidewall 506. In theillustrated example, the grain of the material used for the sidewall 506runs generally horizontal as depicted by the arrows 508. Accordingly,the one or more ribs 504 are disposed on the sidewall to run generallyin the same horizontal direction. The ribs 504 can strengthen thesidewalls 506 to inhibit or even eliminate distortion of the sidewalls506 resulting from heat inside the burner box 108.

According to an aspect of the present disclosure, one or moreembodiments of the super heater system 100 may further include an outletinterface assembly providing a plurality of outlets. FIG. 6 illustratesan outlet interface assembly 602 according to at least one example. Theoutlet interface assembly 602 is coupled with the outlet 304 of the heatexchanger assembly 202 (see FIG. 4). According to an aspect, the outletinterface assembly 602 includes a plurality of outlet interfaces ofdifferent sizes. In the illustrated example, for instance, the outletinterface assembly 602 includes an on-the-fly outlet interface 604 andfour preheat outlet interfaces 606. In at least one example, theon-the-fly outlet interface 604 may have a diameter of about six inches(15.24 cm), and the preheat outlet interfaces 606 may have a diameter ofabout four inches (10.16 cm).

The on-the-fly outlet interface 604 is sized and configured tofacilitate a full flow of the heated liquid. In some implementations,the on-the-fly outlet interface 604 may be employed to connect adischarge hose for immediate or approximately immediate use of theheated liquid by a frac crew. That is, since the super heater system 100is able to heat the liquid to the target temperature at flow rates aboutequal to or even above the rate at which the heated liquid is beingpulled by a frac crew, the heated liquid can be employed by the fraccrew on-the-fly (i.e., without the use of preheated stockpiles ofliquid) or substantially on-the-fly.

The plurality of preheat outlet interfaces 606 enables the super heatersystem 100 to connect a plurality of discharge hoses. The plurality ofpreheat outlet interfaces 606 may be employed for heating a liquid thatis to be stored (or stockpiled) prior to being used by a frac crew. Forexample, the plurality of preheat outlet interfaces 606 may be employedfor coupling a plurality of discharge hoses to one or more frac tanks.In other examples, the plurality of preheat outlet interfaces 606 can beemployed to control the flow of the heated liquid into the storagecontainer. For example, a super heater system 100 may be employed forheating a large open reservoir, typically referred to as a pit. To blendthe heated water with the rest of the water in the reservoir, a currentcan be induced into the reservoir to circulate the water using aplurality of discharge hoses respectively coupled to the plurality ofpreheat outlet interfaces 606 and strategically placed in the reservoir.

Further embodiments of the present disclosure relate to methods ofmaking a super heater system including a heat exchanger assembly, suchas the super heater system 100 including the heat exchanger assembly 202as described above. FIG. 7 is a flow diagram depicting various steps forat least one implementation of such a method. At step 702, a firstheader (e.g., first header 206 in FIG. 2) may be formed. Forming thefirst header may include forming a plurality of header layers (e.g.,header layers 212 as shown in FIG. 3). Each of the header layers of thefirst header can be disposed in alternating fluid communication asdescribed above. At step 704, a second header (e.g., second header 206in FIG. 2) may be formed. Forming the second header may also includeforming a plurality of header layers (e.g., header layers 212 as shownin FIG. 3). Each of the header layers for the second header can also bedisposed in alternating fluid communication. The alternating fluidcommunication of the header layers of the second header can alternatewith the alternating fluid communication of the headers of the firstheader. In at least some implementations, the plurality of header layersfor the first and second headers may be formed with a generally cuboidshape.

At step 706, a plurality of heat exchange coils (e.g., heat exchangecoils 204 in FIG. 2) can be coupled to the first header and the secondheader. For instance, a first longitudinal end of each of the pluralityof heat exchange coils can be coupled to a header layer of the firstheader, and an opposing longitudinal end of each heat exchange coil canbe coupled to a header layer of the second header. As noted above, theheat exchange coils can be coupled to a header by any conventionalmeans, including threaded connections, welds, adhesives, etc., or somecombination of two or more means.

At step 708, a burner manifold (e.g., burner manifold 210 in FIG. 2) canbe disposed adjacent the heat exchange coils. For instance, the burnermanifold can be disposed adjacent the heat exchange coils so that heatgenerated by the burner manifold can be exposed to the heat exchangecoils. In some embodiments, the burner manifold is disposed below theheat exchange coils.

At step 710, a housing (e.g., housing 114 in FIGS. 1 and 5) can bepositioned to at least substantially encircle the first header, thesecond header and the plurality of heat exchange coils. The housing canalso at least substantially encircle the burner manifold. As notedabove, the housing may include insulation and one or more ribs.

Although not depicted in FIG. 7, additional steps may also be included,such as coupling an outlet interface assembly (e.g., outlet interfaceassembly 602 in FIG. 6) to an outlet of the first or second header,coupling a pump (e.g., pump 110, boost pump 112) to an inlet of thefirst or second header, coupling a fuel storage and supply system (e.g.,fuel storage and supply system 106 in FIG. 1) to the burner manifold,disposing the forgoing elements on a trailer (e.g., trailer 102 in FIG.1), and/or coupling the trailer to a vehicle (e.g. vehicle 104 in FIG.1). Furthermore, although the flow diagram depicts the operations as asequential process, at least some of the operations can be performed inparallel or concurrently. In addition, the order of the operations maybe re-arranged.

The various features associate with the examples described herein andshown in the accompanying drawings can be implemented in differentembodiments and implementations without departing from the scope of thepresent disclosure. Therefore, although certain specific constructionsand arrangements have been described and shown in the accompanyingdrawings, such embodiments are merely illustrative and not restrictiveof the scope of the disclosure, since various other additions andmodifications to, and deletions from, the described embodiments will beapparent to one of ordinary skill in the art. Thus, the scope of thedisclosure is only determined by the literal language, and legalequivalents, of the claims which follow.

1. A burner box, comprising: a plurality of heat exchange coils; a firstheader coupled to a first longitudinal end of the plurality of heatexchange coils, the first header comprising a plurality of header layersin alternating direct fluid communication; a second header coupled to anopposing second longitudinal end of the plurality of heat exchangecoils, the second header comprising a plurality of header layers inalternating direct fluid communication; and a burner manifold positionedto expose the plurality of heat exchange coils directly to a flamegenerated from the burner manifold when ignited.
 2. (canceled)
 3. Theburner box of claim 1, wherein the plurality of heat exchange coils areadapted to expose a liquid flowing therethrough to heat generated by theburner manifold flame to increase a temperature of the liquid by between30° and 85° at a rate of 30 barrels per minute or greater.
 4. The burnerbox of claim 1 wherein the plurality of heat exchange coils are adaptedto expose a liquid flowing therethrough to heat generated by the burnermanifold flame to increase a temperature of the liquid by between 30°and 85° at a rate between 30 barrels per minute and 58 barrels perminute.
 5. The burner box of claim 1, wherein each header layer of thefirst header and the second header includes two sublayers of heatexchange coils coupled thereto.
 6. The burner box of claim 1, whereineach of the plurality of header layers of the first header and each ofthe plurality of header layers of the second header comprises agenerally cuboid shape.
 7. The burner box of claim 1, wherein thealternating direct fluid communication of the plurality of header layersfor the first header alternates with the alternating direct fluidcommunication of the plurality of header layers for the second header.8. The burner box of claim 1, wherein the first header comprises sixheader layers, and the second header comprises six header layers.
 9. Asuper heater system, comprising: a fuel storage and supply system; aburner manifold in fluid communication with the fuel storage and supplysystem and adapted to generate heat in the form of a flame by combustingfuel received from the fuel storage and supply system; at least one pumpadapted to pump a fluid; and a heat exchanger assembly in fluidcommunication with the pump to receive the pumped fluid, the heatexchanger assembly comprising: a first header at a first longitudinalend, the first header comprising a plurality of first header layers inalternating direct fluid communication; a second header at a secondlongitudinal end, the second header comprising a plurality of secondheader layers in alternating direct fluid communication; and a pluralityof heat exchange coils extending between and coupled to the first headerand the second header, wherein the plurality of heat exchange coils aredirectly exposed to the flame generated by the burner manifold.
 10. Thesuper heater system of claim 9, wherein each header layer of the firstheader and the second header includes two sublayers of heat exchangecoils coupled thereto.
 11. The super heater system of claim 9, whereineach of the first header layers and each of the second header layerscomprises a generally cuboid shape.
 12. The super heater system of claim9, wherein the alternating direct fluid communication of the pluralityof first header layers alternates with the alternating direct fluidcommunication of the plurality of second header layers.
 13. The superheater system of claim 9, further comprising a housing at leastsubstantially enclosing the heat exchanger assembly and the burnermanifold, the housing comprising at least one rib disposed on a sidewallof the housing to run in a direction of a grain of the sidewall.
 14. Thesuper heater system of claim 9, further comprising an outlet interfaceassembly in fluid communication with the heat exchanger assembly, theoutlet interface assembly comprising: at least one on-the-fly outletinterface adapted to output heated liquid for use in hydraulicfracturing without prior storage; and a plurality of preheat outletinterfaces adapted to output heated liquid for storage prior to use inhydraulic fracturing.
 15. A heat exchanger assembly, comprising: aplurality of heat exchange coils directly exposed to a flame; a firstheader coupled to a first longitudinal end of the plurality of heatexchange coils, the first header comprising a plurality of headerlayers, wherein at least some of the header layers of the first headerare in fluid communication with at least one other header layer of thefirst header; and a second header coupled to an opposing secondlongitudinal end of the plurality of heat exchange coils, the secondheader comprising a plurality of header layers, wherein at least some ofthe header layers of the second header are in fluid communication withat least one other header layer of the second header.
 16. The heatexchanger assembly of claim 15, wherein: header layers of the firstheader in direct fluid communication correspond to header layers of thesecond header not in direct fluid communication; and header layers ofthe second header in direct fluid communication correspond to headerlayers of the first header not in direct fluid communication.
 17. Theheat exchanger assembly of claim 15, wherein the header layers of thefirst header and the second header are each coupled to two sublayers ofheat exchange coils.
 18. The heat exchanger assembly of claim 15,wherein the header layers of the first header and the second header eachcomprises a generally cuboid shape. 19-26. (canceled)